wheel bolt torque TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine PP0FT−01
− PREPARATIONSUPPLEMENTAL RESTRAINT SYSTEM
PP−11 5
1996 TOYOTA T100 (RM449U)
EQUIPMENT
Torque wrench
Bolt: Length: 35mm (1.38 in.) Pitch: 1.0 mm (0.039 in.)
Diam.: 6.0 mm (0.236 in.)Airbag disposal
Tire Width: 185 mm (7.28 in.) Inner diam.: 360 mm (14.17 in.)Airbag disposal
Tire with disc wheel Width: 185 mm (7.28 in.)
Inner diam.: 360 mm (14.17 in.)Airbag disposal
vinyl bagAirbag disposal

Downloaded from www.Manualslib.com manuals search engine SS07U−03
SS−42
− SERVICE SPECIFICATIONSCLUTCH
1996 TOYOTA T100 (RM449U)
TORQUE SPECIFICATION
Part tightenedN·mkgf·cmft·lbf
Clutch line union1515511
Master cylinder installation nut131309
Bleeder plug1111 08
Clutch cover x Flywheel1919514
Release cylinder installation bolt121209
Release fork support 5VZ−FE4748035
Release fork support 3RZ−FE3940029

Downloaded from www.Manualslib.com manuals search engine SS085−01
SS−70
− SERVICE SPECIFICATIONSBRAKE
1996 TOYOTA T100 (RM449U)
TORQUE SPECIFICATION
Part tightenedN·mkgf·cmft·lbf
Master cylinder x Piston stopper bolt101007
Master cylinder x Reservoir1.717.515.2 in.·lbf
Master cylinder x Brake booster131309
Brake line union nut1515511
Brake booster clevis lock nut2526019
Brake booster x Pedal bracket131309
Front disc brake caliper installation bolt 2WD 1.0 ton3940029
2WD 0.5 ton3637027
4WD1231,25090
Bleeder plug1111 08
Front disc brake torque plate x Steering knuckle 2WD1081,10080
Front disc x Front axle hub6465047
Front disc brake caliper x Flexible hose1515511
Rear drum brake wheel cylinder x Backing plate101007
Parking brake bellcrank bracket x Backing plate131309
LSP & BV installation nut131309
LSP & BV x Load Sensing Spring Assembly1818513
Load Sensing Spring Assembly x Shackle No.11818513
Shackle No.1 x Shackle No.22525018
Shackle No.2 x Shackle Bracket131309
LSP & BV x Frame2930011
ABS actuator x ABS actuator bracket5.45548 in.·lbf
ABS actuator bracket x Body1919514
Speed sensor installation bolt8.08271 in.·lbf
Front speed sensor wire harness clamp5.05144 in.·lbf
Rear speed sensor wire harness clamp131309

Downloaded from www.Manualslib.com manuals search engine SS08X−01
− SERVICE SPECIFICATIONSSTEERING
SS−73
1996 TOYOTA T100 (RM449U)
TORQUE SPECIFICATION
Part tightenedN·mkgf·cmft·lbf
STEERING COLUMN
NON−TILT STEERING COLUMN:
Steering wheel set nut3536026
Steering wheel pad set screw (Torx screw)9.09078 in.·lbf
Steering column assembly set bolt and nut2526019
Control shaft lever x Control shaft assembly AT3536026
Intermediate shaft x Control valve assembly 2WD3536026
Intermediate shaft x Worm gear valve assembly 4WD3536026
Sliding w/shaft york sub−assembly x Intermediate shaft3536026
Main shaft assembly x Sliding w/shaft york sub−assembly3536026
TILT STEERING COLUMN:
Steering wheel set nut3536026
Steering wheel pad set screw (Torx screw)9.09078 in.·lbf
Steering column assembly set bolt and nut2526019
Control shaft lever x Control shaft assembly AT3536026
Intermediate shaft x Control valve assembly 2WD3536026
Intermediate shaft x Worm gear valve assembly 4WD3536026
Sliding w/shaft york sub−assembly x Intermediate shaft3536026
Sliding york sub−assembly x Sliding w/shaft york sub−assembly3536026
Main shaft assembly x Sliding york sub−assembly3536026
Turn signal bracket set bolt7.88069 in.·lbf
Tilt lever assembly set bolt22017 in.·lbf
Tilt sub lever side pawl set bolt x nut5.96052 in.·lbf
Tilt lever retainer set nut1515011
Compression spring set bolt7.88069 in.·lbf
PS VANE PUMP
3RZ−FE and 5VZ−FE:
Union bolt x Pressure feed tube4747534
Pressure port union x Pump housing8385061
Bracket x Pump assembly 5VZ−FE4344032
Rear housing set bolt2424017
Oil reservoir set bolt Front131309
Rear2424017
Vane pump pulley set nut4344032
Vane pump assembly set bolt 3RZ−FE3940029
Vane pump assembly with bracket set bolt and nut 5VZ−FE3940029
PS GEAR
2WD:
Control valve housing x Rack housing1818513
Self−locking nut2525018
Rack housing cap6970051
Rack guide spring cap lock nut51 (60)521 (700)38 (51)
Rack x Rack end61 (83)618 (850)45 (62)

Downloaded from www.Manualslib.com manuals search engine Q06793
N
R
P
AT5115
Neutral Basic line
Bolt
Groove
DI−272
− DIAGNOSTICSAUTOMATIC TRANSMISSION
1996 TOYOTA T100 (RM449U)
(3) Return the No.1 gear shifting rod 2 notches to N
position.
(4) Set the shift lever to N position.
(5) While holding the shift lever lightly toward the R
position side, adjust the No.1 gear shifting rod nut.
(6) Tighten the No.1 gear shifting rod nut.
Torque: 25 N·m (260 kgf·cm, 19 ft·lbf)
(7) Start the engine and make sure that the vehicle
moves forward when shifting the lever from the N to
D position and reverses when shifting it to the R
position.
(g) Inspect and adjust the park/neutral position.
Check that the engine can be started with the shift lever
only in the N or P position, but not in other positions.If it
is not as stated above, carry out the following adjustment
procedure.
(1) Loosen the park/neutral position switch bolt and set
the shift lever to the N position.
(2) Align the groove and neutral basic line.
(3) Hold in position and tighten the bolt.
Torque: 13 N·m (130 kgf·cm, 10 ft·lbf)
(h) Check the idle speed.
Idle speed (In N position and air conditioner OFF):
3RZ−FE: 700 ± 50 rpm
5VZ−FE: 700 ± 50 rpm
6. MECHANICAL SYSTEM TESTS
(a) Measure the stall speed.
The object of this test is to check the overall performance of the transmission and engine by measuring
the stall speeds in the D and R positions.
NOTICE:
Do the that at normal operating fluid temperature 50 − 80°C (122 − 176°F)
Do not continuously run this test longer than 5 seconds.
To ensure safety, conduct this test in a wide, clear, level area which provides good traction.
The stall test should always be carried out in pairs. One technician should observe the condi-
tions of wheels or wheel stoppers outside the vehicle while the other is doing the test.
(1) Chock the 4 wheels.
(2) Connect an OBD II scan tool or TOYOTA hand−held tester to DLC3.
(3) Fully apply the parking brake.
(4) Keep your left foot pressed firmly on the brake pedal.
(5) Start the engine.
(6) Shift into the D position. Press all the way down on the accelerator pedal with your right foot.
Quickly read the stall speed at this time.
Stall speed:
3RZ−FE: 1,950 ± 150 rpm
5VZ−FE: 2,150 ± 150 rpm
(7) Do the same test in R position.
Stall speed:
3RZ−FE: 1,950 ± 150 rpm
5VZ−FE: 2,150 ± 150 rpm

Downloaded from www.Manualslib.com manuals search engine Z11443
A
A B
Z11127
(6)(7)
(8) (9)
(10)
(1) (2)
(3)(4) (5)
Z15493
Up ward 90°
Painted Mark
− ENGINE MECHANICAL (3RZ−FE)CYLINDER BLOCK
EM−103
1996 TOYOTA T100 (RM449U)
30. INSTALL REAR END PLATE
Install the rear end plate with the 3 bolts.
Torque:
Bolt A: 18 N·m (185 kgf·cm, 13 ft·lbf)
Bolt B: 20 N·m (200 kgf·cm, 14 ft·lbf)
31. M/T:
INSTALL FLYWHEEL
(a) Install and uniformly tighten 10 new bolts to the flywheel,
in several passes, in the sequence shown.
Torque: 26.5 N·m (270 kgf·cm, 19 ft·lbf)
(b) Mark the top of the flywheel bolt with paint.
(c) Retighten the flywheel bolts by 90° in the numerical order
shown above.
(d) Check that the painted mark is now at a 90° angle to the
top.
32. A/T:
INSTALL DRIVE PLATE
Install the front spacer, drive plate and rear spacer with the 10
bolts.
Torque: 74 N·m (750 kgf·cm, 56 ft·lbf)

Downloaded from www.Manualslib.com manuals search engine P00601
Adhesive
P21461
1
5
3
7
2 68
4
− ENGINE MECHANICAL (5VZ−FE)CYLINDER BLOCK
EM−107
1996 TOYOTA T100 (RM449U)
Parts must be assembled within 5 minutes of ap-
plication. Otherwise the material must be removed
and reapplied.
Immediately remove nozzle from the tube and rein-
stall cap.
(c) Install the bypass pipe with the 2 bolts and nut.
Torque: 8.5 N·m (85 kgf·cm, 75 in.·lbf)
(d) Connect the 2 knock sensor connectors.
29. INSTALL CYLINDER HEADS
30. INSTALL PULLEYS AND TIMING BELT
(See page EM−19)
31. REMOVE ENGINE STAND
32. INSTALL REAR END PLATE
Torque: 7.5 N·m (75 kgf·cm, 66 in.·lbf)
33. A/T:
INSTALL DRIVE PLATE
(a) Apply adhesive to 2 or 3 threads of the mount bolt end.
Adhesive:
Part No. 08833 − 00070, THREE BOND 1324 or equiva-
lent
(b) Install the drive plate on the crankshaft.
(c) Install and uniformly tighten the 8 mount bolts in several
passes, in the sequence shown.
Torque: 85 N·m (850 kgf·cm, 63 ft·lbf)
34. M/T:
INSTALL FLYWHEEL
(a) Apply adhesive to 2 or 3 threads of the mount bolt end.
Adhesive:
Part No. 08833 − 00070, THREE BOND 1324 or equiva-
lent
(b) Install the drive plate on the crankshaft.
(c) Install and uniformly tighten the 8 mount bolts in several
passes, in the sequence shown.
Torque: 85 N·m (850 kgf·cm, 63 ft·lbf)

Downloaded from www.Manualslib.com manuals search engine Z14383B A
B
BB
B
B
LU0609
Seal Packing
− LUBRICATION (5VZ−FE)OIL PUMP
LU−15
1996 TOYOTA T100 (RM449U)
(e) Install the oil pump with the 8 bolts, and ground strap.
Torque:
Bolt A: 20 N·m (200 kgf·cm, 15 ft·lbf)
Bolt B: 42 N·m (420 kgf·cm, 31 ft·lbf)
2. INSTALL CRANK SHAFT POSITION SENSOR
3. INSTALL OIL PAN BAFFLE PLATE
4. INSTALL OIL STRAINER
Place a new gasket and install the oil strainer.
Torque:7.5 N·m (76 kgf·cm, 66 in.·lbf)
5. CLEAN OIL PAN
Remove any old packing (FIPG) material and be careful not to
drop any oil on the contacting surfaces of the, oil pan, cylinder
block and sealing grooves.
Using a razor blade and gasket scraper, remove all
the remaining seal packing (FIPG) material from the
gasket surfaces.
Thoroughly clean all components to remove all the
loose material.
Clean both sealing surfaces with a non−residue sol-
vent.
NOTICE:
Do not use a solvent which will affect the painted surfaces.
6. INSTALL OIL PAN
(a) Apply seal packing to the oil pan, as shown in the illustra-
tion.
Seal packing:
Part No. 08826−00080 or equivalent
Install a nozzle that has been cut to a 3 − 4 mm (0.12
− 0.16 in.) opening.
HINT:
Avoid applying an excess amount to the surface.
If parts are not assembled within 5 minutes of apply-
ing the seal packing, the effectiveness of the seal
packing is lost and the seal packing must be re-
moved and reapplied.
Immediately remove the nozzle from the tube and
reinstall the cap after using the seal packing.
(b) Install the oil pan with the 4 nuts and 15 bolts.
Torque:7.6 N·m (78 kgf·cm, 67 in.·lbf)
7. INSTALL FLYWHEEL HOUSING UNDER AND COVER
DUST
8. INSTALL STIFFENER PLATE
9. CONNECT STARTER WIRE CLAMP
10. A/T:
INSTALL OIL COOLER TUBE AND CLAMP
11. INSTALL CRANKSHAFT TIMING PULLEY
(See page EM−19)

Downloaded from www.Manualslib.com manuals search engine CL02L−01
Q06647
5VZ−FE 3RZ−FE
SST Flywheel
Side
Q06958
1,4
7
3
62,58 Matchmarks
Q06641
SST
Z00762
Q06642
− CLUTCHCLUTCH UNIT
CL−19
1996 TOYOTA T100 (RM449U)
INSTALLATION
1. INSTALL CLUTCH DISC AND CLUTCH COVER ON
FLYWHEEL
(a) Insert SST in the clutch disc, and then set them and the
clutch cover in position.
SST 09301−00110
(b) Align the matchmarks on the clutch cover and flywheel.
(c) Torque the 6 bolts on the clutch cover in the order shown.
Torque: 19 N·m (195 kgf·cm, 14 ft·lbf)
HINT:
Temporarily tighten the No.1 and No.2 bolts.
2. CHECK DIAPHRAGM SPRING TIP ALIGNMENT
Using a dial indicator with roller instrument, check the dia-
phragm spring tip alignment.
Maximum non−alignment: 0.5 mm (0.020 in.)
If alignment is not as specified, using SST, adjust the dia-
phragm spring tip alignment.
SST 09333−00013
3. APPLY MOLYBDENUM DISULPHIDE LITHIUM BASE
GREASE (NLGI NO.2)
(a) Apply release hub grease to the these parts.
Release fork and hub contact point
Release fork and push rod contact point
Release fork pivot point
(b) Apply clutch spline grease.
Clutch disc spline
HINT:
Recommended grease part number 08887−01706 (100g).
4. INSTALL BOOT, RELEASE BEARING AND FORK TO
TRANSMISSION
Install the boot and bearing to the release fork, and then install
them to the transmission.

Downloaded from www.Manualslib.com manuals search engine SA3213
Front AB
D
C
FA0829FA0828F01734
Decrease
Increase
Decrease Increase Front Adjusting Cam
Rear Adjusting Cam
R08116
FA0017
Front
A = B AB
− SUSPENSION AND AXLEFRONT WHEEL ALIGNMENT (4WD)
SA−11
1450 Author: Date:
1996 TOYOTA T100 (RM449U)
4. INSPECT TOE−IN
To e−in (total)
0.5 tonA + B: 0°05’ ± 12’ (0.08° ± 0.2°)
C − D: 1.0 ± 2 mm (0.04 ± 0.08 in.)
Extra cab
P235/75 R15A + B: −0°08’ ± 12’ (−0.14° ± 0.2°)
C − D: −1.9 ± 2 mm (0.07 ± 0.08 in.)
Extra cab
31 x 10.5 R15A + B: −0°08’ ± 12’ (−0.14° ± 0.2°)
C − D: −2.0 ± 2 mm (0.08 ± 0.08 in.)
If the toe−in is not within specification, adjust the tie rod end.
5. ADJUST CAMBER AND CASTER
(a) Loosen the front and/or rear adjusting cam nuts.
(b) Adjust the camber and caster by front and/or rear adjust-
ing cams (See adjustment chart).
HINT:
Try to adjust the camber and caster to the center value.
(c) Torque the front and/or rear adjusting cam nuts.
Torque: 226 N·m (2,300 kgf·cm, 166 ft·lbf)
6. ADJUST TOE−IN
(a) Loosen the clamp bolts and nuts.
(b) Adjust toe−in by turning the left and right tie rod tubes an
equal amount.
HINT:
Try to adjust the toe−in to the center value.
Make sure that the length of the left and right tie rods end
is equal.